Rigid foam board installation clip

ABSTRACT

A clip for facilitating installation of foam insulation boards in a building structure. The clip comprises a body, a spacer and a foot for holding the insulation board, and a connection region for attachment of the clip to a building structural member. The clip is designed to ensure proper ventilation and greatly easy the proper installation of rigid foam insulation.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates generally structural connectors. Moreparticularly, the present invention relates to a clip for attachingrigid foam insulation to a building's structural members.

Description of Related Art

The need for properly installed and correctly located insulation is noteasily met using current construction practices. Rigid foam insulationboard (sometimes referred to as RFB) is, in present common practice,supported by strips of lath (nailers) nailed to the rafters, joists, orbeams between which the insulation board is to be installed. Supportingthe insulation board while attaching the nailers is difficult,especially if the spacing between the rafters, joists, or beams isinsufficient to swing a hammer. Further, precise placement of the naileris difficult. As such, current practices utilize excess material andrequire extensive labor in the milling and installing processes toproperly install the rigid foam insulation board. This difficulty can insome cases lead to injury because of the difficult maneuvers beingperformed on ladders and in off-balance positions. Further, preciseworkmanship of the task is very time consuming and costly. The currentproducts available for providing roof ventilation do not provide a fullyvented space. This lack of venting restricts air flow, and promotesmoisture entrapment which results in potential ice damming, poor indoorair quality and early deterioration of roof sheathing and roofing.

Therefore, what is needed is a more efficient structure and method ofinstalling rigid foam insulation board.

SUMMARY OF THE INVENTION

The subject matter of this application may involve, in some cases,interrelated products, alternative solutions to a particular problem,and/or a plurality of different uses of a single system or article.

In one aspect, a rigid foam insulation board installation clip isprovided. The clip comprises a body having a spacer at its distal end,and a connection region at its proximal end. The spacer has a top and abottom, and has at least a portion of the bottom extending approximatelyperpendicularly from the body. The clip further comprises a foot, thefoot may be fixed, or may be adjustably positionable along the body at adistance away from the spacer. The spacer and foot, when properlypositioned, define a cavity between them, the cavity defined at a topand bottom by the spacer and foot, respectively, having an open frontand sides, and a rear defined by the body.

In another aspect, a foam insulation assembly is provided. Theinsulation assembly comprises a building structural member, and a foaminsulation board connected thereto by a clip. The clip comprises a bodyhaving a connection region, a spacer extending from a distal end of thebody, and a foot. The foot may be fixed, or may be adjustablypositionable along the body at a distance away from the spacer. Thespacer and foot, are oriented to hold the insulation board in place witha spacer bottom abutting one side of the insulation board, and the footabutting the opposite side of the insulation board. The connectionregion of the clip is attached to the building structural member. Thetop of the spacer abuts a sheathing or similar building structure,thereby forming an air space gap between the sheathing and the foaminsulation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 provides a side view of an embodiment of the installation clip inuse.

FIG. 2 provides a side view of an embodiment of the installation clip.

FIG. 3 provides a side view of another embodiment of the installationclip.

FIG. 4 provides a front view of an embodiment of the installation clip.

FIG. 5 provides a top view of an embodiment of the installation clip.

FIG. 6 provides a bottom view of an embodiment of the installation clip.

FIG. 7 provides a front perspective view of an embodiment of theinstallation clip.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appendeddrawings is intended as a description of presently preferred embodimentsof the invention and does not represent the only forms in which thepresent invention may be constructed and/or utilized. The descriptionsets forth the functions and the sequence of steps for constructing andoperating the invention in connection with the illustrated embodiments.

Generally, the present invention concerns a clip that may be attached torigid foam board insulation for building insulation, the clip is alsoconfigured to be attachable to building structural members. As such, theinstallation of rigid foam insulation is greatly facilitated. Thepresent clip invention may be used in any condition where rigid foaminsulation is being installed. For example, the clip may be used in newconstruction, existing buildings, renovations, and the like.

The clip consists of a spacer configured to provide an air spacingbetween a sheathing or flooring and the insulation when installed. Theclip further comprises a foot portion, the foot portion configured topinch or otherwise secure the foam insulation between it and the spacer.A body of the clip may extend downwards away from the spacer and foot.This body is designed to be attached to a building framing or otherstructural member, allowing the foam insulation board to which the clipis attached to be secured in place, and properly spaced from thesheathing. The foot in many embodiments may be slidable along the clipbody allowing the clip to be adjustable for various insulation boardthicknesses. However, it should be understood that the foot may be inany configuration allowing it to secure the insulation board between itand the spacer. For example the foot may screw into place, may flip intoplace, or may be connectable to the body once the insulation board isplaced adjacent to the spacer.

The installation clip contemplated herein is configured to acceptmultiple differently sized foam insulations. For example, the mostcommonly sized insulations have thicknesses of ½ inch, 1 inch, and 1½inch. As such, in one embodiment, the clip may be adjustable to threedistinct positions to accept these three sizes. In further embodiments,the clip may be adjustable to accept other sizes of foam boardinsulation. This adjustability is shown herein by adjustment of the footportion of the clip. However, it should be understood that theadjustability may be achieved in other ways without straying from thescope of the present invention.

The installation clip contemplated herein may be formed of any materialrigid enough to connect to and support the foam insulation board, andresilient enough to be attached to the building structural members. Forexample, materials of which the installation clip may be made include,but are not limited to, hard plastics, wood, metals, compositematerials, ceramics, combinations thereof, and the like.

The installation clip may be any size capable of connecting to andsupporting the foam insulation board. Size may vary depending onapplication, and it should be understood that the sizing of the clip isin no way limited based on the disclosure herein.

The clip may be attached to the building structural members (rafters,joists, beams, etc.) in any manner capable of supporting the insulation.For example, the clip may be mechanically connected to the structuralmembers by fasteners such as nails, staples, screws, tacks, and thelike. In other embodiments, adhesives, pressure connections, and thelike may be employed.

Turning now to FIG. 1, an embodiment of the installation clip in use isshown. A foam insulation board 103 is shown secured between asail-shaped spacer 10 and a foot 12. The spacer 10 abuts a sheathing (ofsub-flooring, roofing, or the like) 101 at its top, abuts a foaminsulation board 103 at its bottom, and is sized to provide an air space102 between the insulation board 103 and sheathing 101. The spacer 10 isshown here as a trapezoid, having a front face sloping inwards from thebottom to the top, the bottom of the spacer extending further from thebody than the top. However, the spacer could be of any shape withoutstraying from the scope of the present invention.

When thoroughly installed, the spacer 10 ensures that there is a uniformdepth of air space between the insulation board 103 and sheathing 101.Foot 12 is configured to be slidable or otherwise positionable along thelength of the clip body 11. In this embodiment, the foot 12 may be slidupward, but once it passes each ramp 15, it can no longer slidedownwards past it. In this embodiment, the ramps 15 allow the foot 12 tostay in place once it is securing the insulation board 103. The foot 12may have a tab that can be urged up by the ramps 15 and then snaps backinto place once it passes over the ramp, thereby preventing the foot 12from passing back over the ramp 15. In the embodiment shown, the ramps15 are specifically spaced so that the clip can receive a 1½ inch thickboard, a 1 inch board, and a ½ inch thick board.

The body 11 of the clip forms an elongate strip that extends downwardfrom where the spacer 10 and foot 12 secure the insulation board 103.This extending strip is configured as a connection region to be attachedto the building structural members to thereby secure the clip andinsulation in place. In the embodiment shown, the body 11 is attached toframing 104 by a plurality of staples 105. As noted above, thisconnection could be made in any way suitable to attach the body 11 toframing 104.

In other embodiments, the foot 12 may be prevented from moving downwardsaway from the spacer 10 in a number of alternative ways. For example,instead of the three large ramps 15 shown in FIG. 1, a plurality ofsmall ramps may allow adjustment of the foot 12 in smaller incrementsupward toward the spacer 10, while still preventing downwards movementof the foot 12. In another embodiment, a threaded connection may allowthe foot 12 to move closer to the spacer 10 while limiting its movementaway from the spacer 10.

The spacer 10 is shown in FIG. 1 as being sail shaped, but it should beunderstood that it may take any shape capable of extending over aportion of the foam insulation board 103 and spacing this connectingarea away from a sheathing or other surface that abuts a top of thespacer 10.

FIGS. 2-7 show another embodiment of the clip in an open position. Theclip has an elongate body 11 with a spacer 10 at a distal end. Thespacer 10 extends away from the body 11 and is configured to hold aninsulation board between it and a foot 12. A bump shaped protrusion 13extends from a bottom surface of the spacer 10, the protrusion 13 mayaid in securing the clip to the foam insulation board (not shown). Afoot 12 is shown at a proximal end of the body 11. This foot 12 isslidable along the body 11. A tab 16 extends into a sliding aperturedefined by the foot 12 allowing the foot 12 to slide along the body 11.The tab is configured to flex or slide over ramps 15 as the foot 12 isslid upward along the body 11 toward the spacer 10. Once the foot 12passes over each ramp 15, the angle of the tab 16 prevents it frommoving back downward. This may aid in the clip holding on to theinsulation board. The foot 12 also has a bump shaped protrusion 14. Thisprotrusion 14 is configured to hold the insulation board tightly. Insome embodiments, the clip body 11 and foot 12 may be separate, and thefoot 12 may be installed on the body 11 during a process wherein theclips are being attached to the foam insulation board.

As further shown in FIGS. 2 and 3, the foot 12 is positionable along thebody 11 at a distance away from the spacer 10 such that the foot 12 andthe bottom of the spacer 10 define a cavity between them, the cavityhaving an open front and sides, and a rear defined by the body 11.

The installation clip described herein may be used in any number ofmanners to secure to foam board insulation and be attached to buildingstructural members. Generally, the steps involved include cutting orotherwise obtaining a properly sized foam insulation board, connectingthe foot to the clip body (if not already attached), placing a bottomface of the spacer, which extends from the clip body, against a piece ofthe rigid foam board insulation, sliding the foot upward towards thespacer until it abuts an opposing face of the insulation, thusconnecting the clip to the insulation, and attaching the clip body to abuilding structural member. In varying embodiments, the step order mayvary, and certain steps may be added or omitted.

In one embodiment, a piece of foam board insulation may have the clipsattached at varying intervals initially at a ground level-forming apre-clipped insulation board. In a particular embodiment, theseintervals may correspond to intervals of the framing or other structuralmember to which the clips will be attached. In another particularembodiment, the clips may be placed at two-foot intervals. Typically,the clips will be attached on the longitudinal edges of the foaminsulation board. This pre-clipped insulation board can then be easilymoved so an installer, who may be at ground level, on a ladder, orotherwise at elevation. The installer can then easily position theinsulation to ensure proper spacing from the sheathing or the likebecause of the spacers. Further, once positioned, the installer caneasily secure the insulation in place by stapling or otherwise securingthe clip bodies to adjacent structural members.

In another embodiment, the installer may connect the clips to theinsulation boards as the board is being installed. In still anotherembodiment, the clips may be connected to the structural members first,and then the foam insulation board may be put in place and connected tothe clips by sliding the foot into a securing position.

In many cases, gaps are created between the foam insulation boards andthe rafters, joists, beams, or the like, to which the insulation boardshave been attached. These gaps may be sealed in any manner. In oneembodiment, the gaps may be sealed with beads of foam sprayed to bridgethese gaps. Framing with irregular centers, or those centers out ofparallel may require individual measuring and cutting of the insulationboard to fit each location. However, even in such cases, the clipsdescribed herein may still be utilized, and the clips may be positionedspecifically based on the configuration of the irregular space.

In further embodiments, the present invention may enhance the operationof radiant floor heating. The use of the installation clips describedherein will result in uniform distance of air space between theinsulation board and the surface beneath which it is suspended. Theclips can be used horizontally beneath sub-floor and radiant tubing toattach the insulation boards between floor joists. This uniform distanceof air space may provide for consistence spacing of radiant heatingcomponents beneath a sub-flooring and may achieve a more uniform floortemperature during the heating season.

Moreover, in some embodiments, the present invention may enhance roofventilation and insulation. The current standard method for roofventilation is attached to the roof deck itself and does not allow afully ventilated cavity, which may introduce ice damming among otherproblems. This standard method has no structural integrity and will onlyallow a loose fill insulation be used to fill the remainder of thecavity as opposed to the foam board insulations with clips taught hereinwhich allows for a dense pack insulation to be used. Thus the presentinvention just allows for a maximized insulating value without thedanger of ice damming. Although there are many roof ventilation methods,there are none that provide the ventilation as described in the use ofthe clips taught herein. Specifically, the use of the installation clipsprovide ventilation vertically at heels of rafters or roof trusses.Further they allow adequate air sealing and blocking for the remainderof the cavity to be filled with dense pack cellulose or another type ofinsulation to provide a desired insulation value. Further still, in someembodiments, the clips may be used beneath a roof deck. Further, thevertical installation of the clips and panels when installed at theheels of roof rafters and trusses are important to conforming to thenational energy code for insulating over exterior wall plates.

While several variations of the present invention have been illustratedby way of example in preferred or particular embodiments, it is apparentthat further embodiments could be developed within the spirit and scopeof the present invention, or the inventive concept thereof. However, itis to be expressly understood that such modifications and adaptationsare within the spirit and scope of the present invention, and areinclusive, but not limited to the following appended claims as setforth. Further, while the clip is described herein as being configuredfor a foam insulation board, it should be understood that the clip maybe used to hold any board or similar elongate element.

What is claimed is:
 1. A foam insulation board installation clipcomprising: a body, the body having a connection region, the body beingmountable to a building structural member; a spacer extending from adistal end of the body, the spacer having a top and a bottom, and aspacing height between the top and the bottom, the top of the spacerbeing a terminal end of the distal end of the clip, wherein the bottomis oriented approximately perpendicular to the body, and is spaced apartfrom the top, wherein the top is approximately perpendicular to a rearface of the body, such that the top and the bottom are approximatelyparallel; a foot, the foot being positioned along the body at a distanceaway from the spacer such that a top of the foot, a front face of thebody, and the bottom of the spacer define a cavity, the cavity having anopen front and sides, a top of the cavity defined by the bottom of thespacer, a bottom of the cavity defined by a top of the foot, and a rearof the cavity defined by the front face of the body.
 2. The foaminsulation board installation clip of claim 1 wherein the foot protrudeslaterally away from the front face of the body.
 3. The foam insulationboard installation clip of claim 1 wherein the spacer protrudeslaterally away from the front face of the body.
 4. The foam insulationboard installation clip of claim 2 wherein the spacer protrudeslaterally away from the front face of the body to a distance away fromthe body that is approximately equal to a distance that the footprotrudes away from the body.
 5. The foam insulation board installationclip of claim 1 wherein the foot is fixedly connected to the body. 6.The foam insulation board installation clip of claim 1 wherein theconnection region is positioned on a part of the body that is on anopposite side of the foot from the spacer.
 7. A foam insulation assemblycomprising: a foam insulation board; a building structural member, thefoam insulation board being connected to the building structural memberby a clip, the clip comprising: a body, the body having a connectionregion; a spacer extending from a distal end of the body, the spacerhaving a top and a bottom, the bottom spaced apart from the top, the topof the spacer being a terminal end of the distal end of the clip,wherein the bottom is oriented approximately perpendicular to the body,and is spaced apart from the top, wherein the top is approximatelyperpendicular to a rear face of the body, such that the top and thebottom are approximately parallel; a foot, the foot being positionedalong the body at a distance away from the spacer such that a top of thefoot, a front face of the body, and the bottom of the spacer define acavity, the cavity having an open front and sides, a top of the cavitydefined by the bottom of the spacer, a bottom of the cavity defined by atop of the foot, and a rear of the cavity defined by the front face ofthe body; the foam insulation board being positioned within the cavitybetween the foot and the spacer bottom; the connection region beingattached to the building structural member; and the top of the spacerabutting a substrate, the spacer forming a gap between the substrate andthe foam insulation board.
 8. The foam insulation assembly of claim 7wherein a fastener connects the connection region to the buildingstructural member, the fastener passing through the connection region ofthe body and into the structural member.
 9. The foam insulation assemblyof claim 7 wherein the gap defines an air space.
 10. The foam insulationassembly of claim 7 wherein the substrate is a sheathing.
 11. The foaminsulation assembly of claim 7 wherein the foot is fixedly connected tothe body.
 12. The foam insulation assembly of claim 7 wherein thestructural member is one of a rafter, a joist, and a beam.
 13. The foaminsulation assembly of claim 7 wherein the foot protrudes laterally awayfrom the front face of the body.
 14. The foam insulation assembly ofclaim 7 wherein the spacer protrudes laterally away from the front faceof the body.
 15. The foam insulation assembly of claim 13 wherein thespacer protrudes laterally away from the front face of the body to adistance away from the body that is approximately equal to a distancethat the foot protrudes away from the body.
 16. The foam insulationassembly of claim 7 wherein the connection region is positioned on apart of the body that is on an opposite side of the foot from thespacer.
 17. The foam insulation assembly of claim 7 wherein theconnection region is an elongate extension which extends in a directionaway from both the spacer and the foot.
 18. A structure comprising thefoam insulation assembly of claim
 7. 19. The structure of claim 18wherein the wherein the foot of the clip is fixedly connected to thebody of the clip.
 20. The structure of claim 18 wherein the connectionregion is positioned on a part of the body that is on an opposite sideof the foot from the spacer.